Diverter conveyor and related methods

TECHNICAL FIELD

This disclosure relates generally to conveyors and, more particularly, to a conveyor for diverting articles being conveyed.

BACKGROUND OF THE INVENTION

Systems for selectively diverting conveyed articles in a direction transverse to the conveying direction are well known. The typical arrangement includes a conveyor associated with a plurality of diverters (sometimes called “carriers”) for engaging the articles. As the conveyor moves in an endless path, an adjacent guide track engages a guide associated with each diverter. In the usual mode of operation, this engagement causes the diverter and the associated article to move laterally along the conveyor. Using such an arrangement advantageously allows for selective placement of the articles into multiple rows or lanes, as necessary or desired for a downstream operation, or alternatively may simply divert selected articles to a takeaway conveyor for further processing.

Currently, most diverter systems are adapted for moving articles from a position along the lateral side of the conveyor across the conveying surface to a position closer to the opposite side of the conveyor. However, it is desirable in some applications to provide for diversion from a central position along the conveying surface to either lateral side of the conveyor, or possibly to allow for the continued unaltered conveyance of the diverter in the central position (which may provide a significant reduction in wear as a result of the lack of a need for specific guidance in such position). Accordingly, a need is identified for a diverter conveyor that addresses and overcomes the foregoing limitations, as well as possibly others.

SUMMARY OF THE INVENTION

One aspect of the invention pertains to an apparatus for intended use in connection with a conveyor for conveying articles in a conveying direction along at least three different paths. The apparatus includes a diverter for moving in the conveying direction along an intermediate path of travel. The diverter includes a plurality of movable guides including a first guide mounted for relative movement to a first position corresponding to a first path of diverter travel closer to one side of the conveyor and a second guide mounted for relative movement to a second position corresponding to a second path of diverter travel closer to a second side of the conveyor. A switch includes a first condition for engaging the first guide to cause the diverter to follow the first path, a second condition for engaging the second guide to cause the diverter to follow the second path, or a third condition for allowing the diverter to follow the intermediate path of travel.

In one embodiment, the switch comprises a first portion adapted for engaging the first guide in the first position and a second portion adapted for engaging the second guide in the second position. An actuator may be provided for moving the first portion of the switch to engage the first guide and the second portion of the switch to engage the second guide. A limiter may also be provided for limiting the stroke of the actuator. The actuator may comprise a first actuator connected to the first portion of the switch and a second actuator connected to the second portion of the switch.

A first magnetic coupling may be provided for holding the first guide in either the first position or the second position, and a second magnetic coupling for holding the second guide in either the first position or the second position. A reset guide upstream of the switch may be provided for moving the first guide to the second position and the second guide to the first position. A first divider downstream of the switch may be provided for engaging the first guide in the first position and a second divider downstream of the switch may be provided for engaging the second guide in the second position. A dead zone may be provided between the switch and the first or second dividers.

A method for conveying articles in a conveying direction along a first path of travel or a second path of travel is also disclosed. The method comprises conveying a diverter including a plurality of guides including a first guide mounted for movement to a first position adjacent one side of the diverter corresponding to the first path of travel and a second guide mounted for movement to a second position adjacent another side of the diverter corresponding to the second path of travel. The method further comprises holding each guide in either the first position or the second position by way of a magnetic coupling between the diverter and the guide. The method may further include the step of moving the guide between the first and second positions.

A further aspect of the disclosure pertains to an apparatus for intended use in connection with a conveyor for conveying articles in a conveying direction. The apparatus comprises at least one diverter for moving in the conveying direction along a central path of travel. The diverter includes a first movable guide mounted for relative movement to a first position corresponding to a first path of diverter travel closer to one side of the conveyor and a second position corresponding to the central path of travel. A switch is provided for engaging the first guide to cause the diverter to follow the first path.

In one embodiment, the diverter includes a second guide mounted for relative movement to a third position corresponding to a second path of diverter travel closer to one side of the conveyor and a fourth position. The switch may comprise a first portion adapted for engaging the first guide in the first position and a second portion adapted for engaging the second guide in the third position. An actuator may be provided for moving the first portion of the switch to engage the first guide and the second portion of the switch to engage the second guide, and a limiter for limiting the stroke of the actuator. The actuator may comprise a first actuator connected to the first portion of the switch and a second actuator connected to the second portion of the switch.

A first magnetic coupling may be provided for holding the first guide in either the first position or the second position. A reset guide may be provided upstream of the switch for moving the first guide to the second position. A first divider downstream of the switch may be provided for engaging the first guide in the first position.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIGS. 1 and 1</figref><i>a </i>are top and bottom perspective views of a conveyor for use in connection with the diverter forming one of the many inventions described herein;

<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of a diverter including two guides;

<figref idref="DRAWINGS">FIGS. 3 and 4</figref> are top and perspective views of a switch, illustrating in particular the guides for traversing a switch;

<figref idref="DRAWINGS">FIGS. 5 and 6</figref> are top and perspective views of the switch of <figref idref="DRAWINGS">FIG. 3</figref>, illustrating in particular reset guides;

<figref idref="DRAWINGS">FIGS. 7-10</figref> are top and perspective views of the switch of <figref idref="DRAWINGS">FIG. 3</figref>, illustrating in particular the switch in a first condition;

<figref idref="DRAWINGS">FIGS. 11-14</figref> are top and perspective views of the switch of <figref idref="DRAWINGS">FIG. 3</figref>, illustrating in particular the switch in a second condition;

<figref idref="DRAWINGS">FIGS. 15-18</figref> are top and perspective views of the switch of <figref idref="DRAWINGS">FIG. 3</figref>, illustrating in particular the switch guides in a third condition;

<figref idref="DRAWINGS">FIGS. 19-21</figref> are perspective views of the actuator illustrating the various positions; and

<figref idref="DRAWINGS">FIGS. 22 and 23</figref> illustrate a toggle position rest zone.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to <figref idref="DRAWINGS">FIG. 1</figref>, which illustrates a diverter system <b>10</b> for use in diverting articles being conveyed. The system <b>10</b> as shown includes a driven conveyor <b>12</b> comprised of a first endless conveyor <b>14</b> (including a chain; not shown), a second endless conveyor <b>16</b> spaced from the first chain, one or more associated diverters <b>20</b> for supporting or engaging the article(s) being conveyed (preferably, on its upper or article engaging surface S), and diverter support (in the form of transverse rods <b>18</b>) positioned between the conveyors <b>14</b>, <b>16</b>. In the illustrated embodiment, the association with the support rods <b>18</b> is such that the diverter <b>20</b> is capable of slidably moving relative to the support in a transverse or lateral direction T relative to the conveying or longitudinal direction C along a forward run in response to the influence of an externally applied force in order to divert articles transversely across the conveying surface (such as for forming lanes on a downstream conveyor, or for moving selected articles onto an associated takeaway conveyor (not shown)). The details of an exemplary diverter construction may be found in Applicant's international patent application PCT/US05/003497, the disclosure of which is incorporated herein by reference, as well as in U.S. Pat. No. 7,690,496, which is also incorporated herein by reference.

Viewing also <figref idref="DRAWINGS">FIG. 2</figref>, each diverter <b>20</b> may be associated with a guide assembly <b>22</b> for use in causing it to move selectively in the transverse direction T (or not) depending on its association with a corresponding guide structure (as will be discussed in more detail below). This guide assembly <b>22</b> may mount to the underside of the diverter <b>20</b>, such as by using fasteners, as outlined in the '496 patent. The guide assembly <b>22</b> includes a pair of guide bodies <b>26</b><i>a</i>, <b>26</b><i>b</i>, each associated with a movably mounted guide <b>28</b><i>a</i>, <b>28</b><i>b </i>positioned in an associated recess or cavity. Each guide <b>28</b><i>a</i>, <b>28</b><i>b </i>is mounted for movement within the recess or cavity between a first position and a second position, the significance of which will be outlined in the following description.

In order to maintain the guide <b>28</b><i>a</i>, <b>28</b><i>b </i>in either the first or second position, and thus determine the path of travel in the conveying direction C, a magnetic coupling may be provided. This magnetic coupling may be formed between the corresponding parts of the bodies <b>26</b><i>a</i>, <b>26</b><i>b </i>of the diverter <b>20</b> and the associated guides <b>28</b><i>a</i>, <b>28</b><i>b</i>. In the illustrated embodiment, and as perhaps best understood viewing <figref idref="DRAWINGS">FIG. 3</figref>, this is accomplished by associated magnets M positioned in the bodies <b>26</b><i>a</i>, <b>26</b><i>b </i>and forming the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>of a magnetic material for forming the desired magnetic coupling, and most preferably comprises a ferromagnetic material. However, the opposite arrangement could also be used instead.

Turning now to <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, the details of a switch <b>30</b> for switching the position of the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>is shown. Firstly, it is noted that the switch <b>30</b> includes optional spaced body guides <b>32</b><i>a</i>, <b>32</b><i>b</i>, which are designed to receive and guide the diverters <b>20</b> as a result of the engagement with the corresponding guide bodies <b>26</b><i>a</i>, <b>26</b><i>b </i>(It should be understood that the diverter <b>20</b> in <figref idref="DRAWINGS">FIG. 4</figref> is showed spaced from the conveyor <b>12</b> for purposes of illustration only). Thus, the body guides <b>32</b><i>a</i>, <b>32</b><i>b </i>may be considered to provide a centering function for the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>relative to the switch <b>30</b>. As can be appreciated from viewing <figref idref="DRAWINGS">FIG. 5</figref>, the end of the body guides <b>32</b><i>a</i>, <b>32</b><i>b </i>may be rounded and thus used for transitioning the diverters <b>20</b> from the return to the forward run of the conveyor <b>12</b> (see action arrow N).

The switch <b>30</b> also includes reset guides <b>34</b><i>a</i>, <b>34</b><i>b</i>, <b>34</b><i>c</i>, as shown in <figref idref="DRAWINGS">FIGS. 5 and 6</figref>. These guides <b>34</b><i>a</i>-<b>34</b><i>c </i>engage the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>and force them to a default position, which in this embodiment corresponds to a central position relative to the lateral sides of the conveyor <b>12</b> when the switch <b>30</b> is in the home condition. Hence, with reference to <figref idref="DRAWINGS">FIGS. 7 and 8</figref>, an upstream actuator <b>36</b> in a home position allows the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>of the diverter <b>20</b> (guide <b>28</b><i>a </i>in the second position, and guide <b>28</b><i>b </i>in the first position) to pass downstream through the switch unaffected, and results in no diversion activity. In other words, downstream dividers <b>38</b><i>a</i>, <b>38</b><i>b </i>(see <figref idref="DRAWINGS">FIGS. 9 and 10</figref>) are not engaged and the diverter <b>20</b> travels past the switch <b>30</b> in the home or intermediate position.

However, in alternate positions of the actuator <b>36</b>, a first portion <b>36</b><i>a </i>(which is tapered in the conveying direction C) is moved (note position <b>36</b><i>a</i>′) to cause the guide <b>28</b><i>a </i>in the first position to divert, as shown in <figref idref="DRAWINGS">FIGS. 11 and 12</figref>. As a result of downstream guidance provided by the divider <b>38</b><i>a</i>, the diverter <b>20</b> is caused to move from the home or intermediate position along a path of travel toward a position closer to one lateral side of the conveyor <b>12</b>, as shown in <figref idref="DRAWINGS">FIGS. 13 and 14</figref> (note arrow L for left). The opposite guide <b>28</b><i>b </i>remains unaffected.

Likewise, in another position of the actuator <b>36</b>, a second portion <b>36</b><i>b </i>(also tapered) is moved (note position <b>36</b><i>b</i>′) to cause the guide <b>28</b><i>b </i>to divert to a second position, as shown in <figref idref="DRAWINGS">FIGS. 15 and 16</figref>. As a result of downstream guidance provided by the divider <b>38</b><i>b</i>, the diverter <b>20</b> is caused to move from the home or intermediate position toward a second path of travel closer to another lateral side of the conveyor <b>12</b>, as shown in <figref idref="DRAWINGS">FIGS. 17 and 18</figref> (note arrow R for right). The opposite guide <b>28</b><i>a </i>remains unaffected.

Details of one possible construction of the actuator <b>36</b> are shown in <figref idref="DRAWINGS">FIGS. 19-21</figref>. It can be understood that the actuator comprises a pair of linear actuators, such as pressurizable cylinders <b>40</b><i>a</i>, <b>40</b><i>b</i>, associated with each portion <b>36</b><i>a</i>, <b>36</b><i>b </i>of the actuator <b>36</b>. When both cylinders <b>40</b><i>a</i>, <b>40</b><i>b </i>are fully extended, as shown in <figref idref="DRAWINGS">FIG. 21</figref>, the portions <b>36</b><i>a</i>, <b>36</b><i>b </i>are brought together and the diverter <b>12</b> position remains unchanged, as described in the foregoing discussion. When each cylinder <b>40</b><i>a </i>or <b>40</b><i>b </i>is retracted, the corresponding portions <b>36</b><i>a</i>, <b>36</b><i>b </i>assume a corresponding position for engaging the guide <b>28</b><i>a</i>, <b>28</b><i>b </i>and causing diversion (compare <figref idref="DRAWINGS">FIGS. 19 and 20</figref>). Floating stroke limiting rods <b>42</b> connecting the portions <b>36</b><i>a</i>, <b>36</b><i>b </i>and with oversized heads prevent the cylinders <b>40</b><i>a</i>, <b>40</b><i>b </i>from causing actuation to a position in which a crash would occur as the result of simultaneous actuation.

Turning to <figref idref="DRAWINGS">FIGS. 22 and 23</figref>, it is also noted that a zone Z is provided downstream of the actuator <b>36</b> for allowing the guides <b>28</b><i>a</i>, <b>28</b><i>b </i>to assume the proper condition (as the result of the magnetic coupling) prior to being engaged by the dividers <b>38</b><i>a</i>, <b>38</b><i>b</i>. The particular length of the zone in the conveying direction may be adjusted depending on the speed of operation.

Finally, <figref idref="DRAWINGS">FIGS. 1 and 1</figref><i>a </i>illustrate the downstream guidance that may be provided. Specifically, along the forward run, guide rails <b>44</b><i>a</i>, <b>44</b><i>b </i>cause the movement of the diverters to the desired position, such as along the left or right side of the conveyor <b>12</b>. Likewise, guide rails <b>46</b><i>a</i>, <b>46</b><i>b </i>along the return run cause the diverters <b>20</b> to return to the central position. As should be appreciated, the position of the guides <b>26</b><i>a</i>, <b>26</b><i>b </i>is not relevant for continued operation, since it will be reset prior to entering the switch <b>30</b>.

Numerous advantages flow from practicing the foregoing teachings. Aside from the simplicity, an advantage of the proposed approach is that it avoids the need for moving a diverter from along one lateral side of the conveyor to another. Rather, the diverter can be moved from the central or intermediate position to either side, which will decrease the longitudinal distance required to make the diversion. The central location and the lack of guidance in the intermediate position also eliminate the past problem of constant friction and resulting wear. The particular nature of the actuator <b>36</b> also helps to avoid the possibility of collisions and ensure that proper guidance is achieved in a reliable manner, thus allowing for the desired high speed of operation to be achieved in order to answer modern throughput demands.

With the exceptions described above for forming the magnetic coupling, the diverter <b>20</b> and its associated components may be formed of any durable material, with UHMW polyethylene, polypropylene or Acetal being preferred choices because of the high durability, relatively low weight, and low cost of such materials. Using these materials results in a substantially strong structure for contacting the articles, and one not prone to oxidation and rust. However, the diverter <b>20</b> and other components may be formed of any material, including metal or other polymers, without limitation.

The foregoing descriptions of various embodiments of the invention are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the art to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention.